autosen AF004 User manual

Operating instructions
Electronic level sensor
autosen AF004
80259948 00 12/2016
Made in Germany
UK

2
Contents
1 Preliminary note���������������������������������������������������������������������������������������������������4
1�1 Symbols used ������������������������������������������������������������������������������������������������4
2 Safety instructions �����������������������������������������������������������������������������������������������4
3 Items supplied������������������������������������������������������������������������������������������������������5
4 Functions and features ����������������������������������������������������������������������������������������7
4�1 Operation with single probe���������������������������������������������������������������������������7
4�2 Operation with coaxial probe �������������������������������������������������������������������������7
4�3 Applications ���������������������������������������������������������������������������������������������������8
4�3�1 Restriction of the application area ��������������������������������������������������������8
5 Function���������������������������������������������������������������������������������������������������������������9
5�1 Measuring principle ���������������������������������������������������������������������������������������9
5�2 Features of the unit��������������������������������������������������������������������������������������10
5�2�1 Easy set-up�����������������������������������������������������������������������������������������10
5�2�2 Display functions ��������������������������������������������������������������������������������10
5�2�3 Switching functions�����������������������������������������������������������������������������10
5�2�4 Offset for indicating the real level in the tank�������������������������������������� 11
5�2�5 Probes for different tank heights��������������������������������������������������������� 11
5�2�6 Safe state �������������������������������������������������������������������������������������������12
5�3 IO-Link ���������������������������������������������������������������������������������������������������������12
6 Installation����������������������������������������������������������������������������������������������������������13
6�1 Installation location / environment ���������������������������������������������������������������13
6�1�1 Unit with single probe �������������������������������������������������������������������������13
6�1�2 Unit with coaxial probe �����������������������������������������������������������������������16
6�2 Installation of the probe �������������������������������������������������������������������������������16
6�2�1 Installation of the rod ��������������������������������������������������������������������������17
6�2�2 Installation of the coaxial pipe ������������������������������������������������������������18
6�3 Shortening of the probe �������������������������������������������������������������������������������19
6�3�1 How to shorten the rod and determine its length L�����������������������������19
6�3�2 Shortening of the coaxial pipe ������������������������������������������������������������19
6�3�3 Determination of the rod length L when coaxial probes are used�������20
6�4 Installation of the unit with single probe�������������������������������������������������������20
6�4�1 Installation in closed metal tanks (without flange plate) ���������������������21
6�4�2 Installation in closed metal tanks (with flange plate) ��������������������������21
6�4�3 Installation in open tanks ��������������������������������������������������������������������22

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6�4�4 Installation in plastic tanks������������������������������������������������������������������23
6�5 Installation of the unit with coaxial probe in the tank �����������������������������������23
6�6 Alignment of the sensor housing �����������������������������������������������������������������24
7 Electrical connection������������������������������������������������������������������������������������������24
8 Operating and display elements ������������������������������������������������������������������������25
9 Menu������������������������������������������������������������������������������������������������������������������26
9�1 Menu structure���������������������������������������������������������������������������������������������26
9�2 Explanation of the menu������������������������������������������������������������������������������27
10 Parameter setting ��������������������������������������������������������������������������������������������28
10�1 Parameter setting in general ���������������������������������������������������������������������28
10�2 Basic settings (unit on delivery)�����������������������������������������������������������������30
10�2�1 Entering the probe length �����������������������������������������������������������������30
10�2�2 Setting to the medium�����������������������������������������������������������������������30
10�2�3 Entering the type of probe used �������������������������������������������������������30
10�3 Configuration of the display �����������������������������������������������������������������������31
10�4 Offset setting����������������������������������������������������������������������������������������������31
10�5 Setting of output signals ����������������������������������������������������������������������������31
10�5�1 Setting of the output function������������������������������������������������������������31
10�5�2 Set the switching limits (hysteresis function) ������������������������������������31
10�5�3 Set the switching limits (window function) ����������������������������������������32
10�5�4 Setting of the switch-off delay�����������������������������������������������������������32
10�5�5 Response of the outputs in case of a fault ���������������������������������������32
10�5�6 Setting of the delay time after signal loss �����������������������������������������32
10�6 Reset all parameters to factory setting ������������������������������������������������������32
10�7 Changing basic settings ����������������������������������������������������������������������������33
10�7�1 Re-enter the probe length�����������������������������������������������������������������33
10�7�2 Setting to another medium ���������������������������������������������������������������33
10�7�3 New entering of the type of probe used��������������������������������������������33
11 Operation ���������������������������������������������������������������������������������������������������������34
11�1 Operating indicators ����������������������������������������������������������������������������������34
11�2 Read the set parameters ���������������������������������������������������������������������������34
11�3 Changing the display unit in the Run mode �����������������������������������������������34
11�4 Error indications�����������������������������������������������������������������������������������������35
11�5 Output response in different operating states��������������������������������������������36
12 Technical data and scale drawing��������������������������������������������������������������������36
12�1 Setting ranges ������������������������������������������������������������������������������������������36

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1 Preliminary note
1.1 Symbols used
►Instructions
> Reaction, result
[…] Designation of keys, buttons or indications
→Cross-reference
Important note
Non-compliance may result in malfunction or interference�
Information
Supplementary note�
2 Safety instructions
• Please read this document prior to set-up of the unit� Ensure that the product is
suitable for your application without any restrictions�
• If the operating instructions or the technical data are not adhered to, personal
injury and/or damage to property can occur�
• Improper or non-intended use may lead to malfunctions of the unit or to
unwanted effects in your application� That is why installation, electrical
connection, set-up, operation and maintenance of the unit must be carried out
by qualified personnel authorised by the machine operator�
• In order to guarantee the correct operation of the unit, it is necessary to use the
unit in media to which it is sufficiently resistant (→ Technical data).
13 Servicing����������������������������������������������������������������������������������������������������������37
14 Applications������������������������������������������������������������������������������������������������������38
14�1 Minimum level monitoring with early warning and alarm ���������������������������38
14�2 Pumping station / empty the tank with overflow protection������������������������39
14�3 Storage tank ����������������������������������������������������������������������������������������������40
15 Factory setting �������������������������������������������������������������������������������������������������41

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• The responsibility as to the suitability of the unit for the application lies with the
operator� The manufacturer assumes no liability for consequences of misuse by
the operator�
• Improper installation and use of the unit result in a loss of the warranty claims
• The unit may cause radio interference in domestic areas� If interference occurs,
the user must take appropriate remedial actions�
• The unit complies with the standard EN 61000-6-4 and is a class A product�
The radiated energy of the microwaves is, for example, much below that of
mobile phones� According to the current state of science the operation of the
unit can be classified to be harmless to human health�
3 Items supplied
• Level sensor AF004
• Operating instructions
In addition, the following is necessary for installation and operation:
• 1 rod (for operation of the unit with single probe → 4.1)
• plus 1 coaxial pipe (for operation of the unit with coaxial probe → 4.2)
• mounting material (if necessary, a launching plate → 4.1)

6
The following components are available as accessories:
Rods Length (cm / inch) Order number
45 / 17,7 AA926
70 / 27,6 AA927
100 / 39,4 AA928
160 / 63�0 AA944
Coaxial pipes
with process connection G¾ Length (cm / inch) Order number
45 / 17�7 AA929
70 / 27�6 AA930
100 / 39�4 AA931
160 / 63�0 AA945
Flange plates Size / process connection Order number
73 - 90 / G¾ AA941
65 - 80 / G¾ AA942
Only use rods and coaxial pipes from autosen gmbh� The optimum
function is not ensured when using components from other manufacturers�

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4 Functions and features
The unit continuously detects the level in tanks and generates output signals
according to the parameter settings�
2 switching outputs are available� They can be set separately�
4.1 Operation with single probe
The single probe is made up of one individual rod� Operation with single probe is
suited for the detection of aqueous media, in particular of heavily soiled aqueous
media�
For the correct function when used with single probe, the unit needs a
large enough metal launching plate� It is necessary for transferring the
microwave pulse to the tank with optimum transmission power�
The flange plates that are available as accessories are not sufficient as
launching plates (for suitable launching plates → 6.4).
For installation in closed metal tanks, the tank lid serves as a launching
plate� For installation in open metal tanks, tanks made of plastic or metal
tanks with plastic lids a sufficiently large fixing plate, a metal plate or
similar must be used (→ 6.4.3 / → 6.4.4).
For operation with single probe, minimum distances to tank walls, objects
in the tank, bottom of the tank and further level sensors must be adhered
to (→ 6.1.1).
4.2 Operation with coaxial probe
The coaxial probe is made up of an inner rod and an outer probe pipe
(coaxial pipe)� The rod is centred in the coaxial pipe by one or several spacers�
In case of operation with a coaxial probe media with a low dielectric constant
(e�g� oil and oil-based media) are detected in addition to aqueous media�
No launching plate is required for operation with coaxial probe�
Furthermore, no minimum distances to tank walls and objects in the tank
are required�

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4.3 Applications
• Water, water-based media
• Oils, oil-based media (only for operation with coaxial probe)
Application examples:
• Detection of coolant emulsion in a machine tool�
• Detection of cleaning liquid in a parts cleaning system�
• Monitoring of hydraulic oil in a hydraulic power unit (only for operation with
coaxial probe)�
4.3.1 Restriction of the application area
Incorrect measurements or signal loss may be caused by the following
media:
- Highly absorbing surfaces (e�g� foam)�
- Intensely bubbling surfaces�
- Media which are very inhomogeneous, separate from each other thus
forming separation layers (e�g� oil layer on water)�
►Check the function by performing an application test�
► Installation in a steady area (→ 6.1).
> In case of signal loss, the unit displays [E�033] and switches the
outputs to a defined state (→ 11.5).
• The unit is not suitable for bulk materials (e�g� plastic granulates)�
• If the unit is to be used in acids or alkalis, in hygienic areas or in electroplating
applications: first check the compatibility of the product materials (→ 12
Technical data and scale drawing) with the media to be monitored�
• The unit is not suitable for applications where the probe is subjected to
permanent and high mechanical stress (e�g� strongly moving viscous media or
strongly flowing media)�
• In case of operation with single probe: use preferably in metal tanks� When
installed in plastic tanks, deterioration caused by electromagnetic interference
may occur (noise immunity according to EN61000-6-2)�
Corrective measures: → 6.4.4.
• In case of operation with coaxial probe: not suitable for soiled or viscous media
and media prone to formation of deposit�
Maximum viscosity: 500 MPa
·
s�

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5 Function
5.1 Measuring principle
Fig. 5-1 Fig. 5-2
D
The unit operates to the principle of guided wave radar� It measures the level
using electromagnetic pulses in the nanosecond range�
The pulses are transmitted by the sensor head and guided along the rod (fig� 5-1)�
When they hit the medium to be detected they are reflected and guided back
to the sensor (fig� 5-2)� The time between transmitting and receiving the pulse
directly relates to the travelled distance (D) and the current level� The reference for
distance measurement is the lower edge of the process connection�
The figures show operation with single probe� In case of operation with a
coaxial probe, the guided wave runs only along the inside of the coaxial
pipe�

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5.2 Features of the unit
5.2.1 Easy set-up
• When the unit is supplied with operating voltage for the first time, the probe
length, the medium to be detected and the type of probe used must be entered�
Then the unit is ready for operation (→ 10.2).
• If necessary, parameters for the output signals and optimisation of the
monitoring functions can be set (→ 10.3 to → 10.5).
• All settings can also be carried out before installation of the unit�
• Reset to the factory settings is possible�
• Electronic lock can be set to prevent unintentional operations�
5.2.2 Display functions
The unit displays the current level, either in cm, inch or in percent of the final
value of the measuring range� Factory setting: cm� The display unit is defined by
programming (→ 10.3). In the Run mode, it can be temporarily switched between
length indication (cm / inch) and percentage:
►briefly press [Set]�
> The selected unit is displayed for 15 s, the corresponding LED is lit� With each
push of the button the display type is changed�
The set unit of measurement and the switching status of the outputs are indicated
by LEDs�
5.2.3 Switching functions
The unit signals via two switching outputs OUT1 / OUT2 that a set limit level
has been reached or that the level is below the limit value� For each output the
following switching functions can be selected:
• Hysteresis function / normally open (fig� 5-3): [OUx] = [Hno]�
• Hysteresis function / normally closed (fig� 5-3): [OUx] = [Hnc]�
First the set point (SPx) is set, then the reset point (rPx) with the requested
difference�

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• Window function / normally open (fig� 5-4): [OUx] = [Fno]�
• Window function / normally closed (fig� 5-4): [OUx] = [Fnc]�
The width of the window can be set by means of the difference between
FHx and FLx� FHx = upper value, FLx = lower value�
Fig. 5-3 Fig. 5-4
L = level; HY = hysteresis; FE = window
• For each switching output a switch-off delay of max� 60 s can be set (e�g� for
especially long pump cycles)�
5.2.4 Offset for indicating the real level in the tank
The zone between tank bottom and lower edge of the probe can be entered as
offset value [OFS]� So display and switch points refer to the actual level�
5.2.5 Probes for different tank heights
• The unit can be installed in tanks of different sizes� Probes in different lengths
are available� To adapt to the tank height, each probe can be shortened� The
minimum probe length is 10 cm, the maximum probe length is 160 cm�
• Probe and housing can be rotated without restriction� This enables easy
installation and orientation of the head of the unit after installation�

12
5.2.6 Safe state
• In case of a fault a safe state can be defined for each output�
• If a fault is detected or if the signal quality is below a minimum value, the
outputs pass into the "safe state"� For this case the response of the outputs can
be set via the parameters [FOU1], [FOU2]�
• Temporary loss of signal caused e�g� by turbulence or foam formation can be
suppressed by a delay time (→ 10.5.6 [dFo]). During the delay time the last
measured value is frozen� If the measured signal is received again in sufficient
strength within the delay time, the unit continues to work in normal operation�
If, however, it is not received again in sufficient strength within the delay time,
the outputs pass into the safe state�
In case of heavy foam formation and turbulence, note the examples of how
to create a steady area (→ 6.1.2).
5.3 IO-Link
General information
This unit has an IO-Link communication interface which requires an IO-Link-
capable module (IO-Link master) for operation�
The IO-Link interface enables direct access to the process and diagnostic data
and provides the possibility to set the parameters of the unit during operation� In
addition communication is possible via a point-to-point connection with a USB
adapter cable�
Further information about IO-Link is available at www� �com�
Device-specific information
You will find the IODDs necessary for the configuration of the IO-Link unit and
detailed information about process data structure, diagnostic information and
parameter addresses at www�autosen�com�
Parameter setting tools
You will find all necessary information about the required IO-Link hardware and
software at www�autosen�com�

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6 Installation
6.1 Installation location / environment
• Vertical installation from the top is preferred�
6.1.1 Unit with single probe
• For a safe function, the unit requires a launching plate (→ 6.4).
• For optimum operation the unit is to be installed as near as possible to the tank
wall� Distance between the rod and the tank wall: minimum 40 mm, maximum
300 mm�
• The following minimum distances between the rod and tank walls, objects in
the tank (B), tank bottom and other level sensors must be adhered to:
50mm
10mm
100mm
B40mm
• For tank walls which are not straight, steps, supports or other structures in the
tank a distance of 50 mm to the tank wall must be adhered to�
• For probe lengths > 70 cm the rod can be considerably deflected by movement
of the medium� To avoid contacting the tank wall or other structures in the tank
in such cases, the minimum distances should be increased�
Reference values:
Probe length Distance to the tank wall or structures in the tank
70���100 cm 100 mm
100���160 cm 180 mm
• If the medium is strongly polluted, there is the risk that a bridge forms
between the rod and the tank wall or structures in the tank� To avoid incorrect

14
measurements: adhere to increased minimum distances depending on type
and intensity of the soiling�
• For installation in pipes:
- The inside pipe diameter (d) must be at least 100 mm (fig� 6-1)�
- Only install the unit in metal pipes�
• For installation in connection pieces:
- The diameter of the boss (d) must be at least 60 mm (fig� 6-2)�
- The height of the boss (h) must not exceed 40 mm (fig� 6-2)�
Although the unit can be installed in a boss, installation in a flat tank lid is
recommended� A boss will impede the distribution of the microwaves�
Fig. 6-1 Fig. 6-2
d
d
h
• Do not install the unit in the immediate vicinity of a fill opening (fig� 6-3)�
If possible, install a fill pipe (A) in the tank (fig� 6-4)� Minimum distance between
the fill pipe and the rod = 50 mm; higher for probe lengths > 70 cm and in case
of heavy soiling (→ 6.1.1).

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Fig. 6-3 Fig. 6-4
50mm
A
To avoid incorrect measurements in case of heavy foam formation and
turbulence:
►if possible, install the sensor in a steady area�
Example how to create a steady area:
- Use of a coaxial probe (only for clean, low-viscosity media)
- Installation in bypass or still pipe (see fig� 6-5)
- Separation of the installation location by metal sheets / perforated sheets
(without figure)
Minimum diameter of the bypass and still pipe: d = 100 mm�
The upper access to the steady area (fig� 6-5: A / B) has to be above
the maximum level� The lower access (fig� 6-5: C / D) or the area with
perforated sheet etc� has to be below the minimum level� This ensures
that neither foam nor turbulence impact the sensor zone� When perforated
sheets or the like are used, soiling (e�g� by metal swarf, particles, ���) can
also be avoided�

16
Fig.: 6-5
d
d
AB
CD
6.1.2 Unit with coaxial probe
• No minimum distances to the tank wall and the
baffles (B) are required�
• Minimum distance to the bottom of the tank:
10 mm�
• The vent hole (A) must not be covered by
mounting elements or similar�
• Do not install the unit in the immediate vicinity of
a fill opening� No water jets must enter into the
holes of the coaxial pipe�
A
B
10 mm
• Note in case of foam formation: the vent of the coaxial pipe must be above the
maximum level� The lower edge of the coaxial pipe must be below the minimum
level�
6.2 Installation of the probe
Rod and coaxial pipe are not included in the scope of delivery� They must be
ordered separately (→ 3 Items supplied).

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6.2.1 Installation of the rod
Fixing of the rod:
►Screw the rod to the unit and tighten it�
Recommended tightening torque: 4 Nm�
For ease of installation and removal the rod
connection can be rotated without restriction� Even
if rotated several times there is no risk of damage to
the unit�
6
In case of high mechanical stress (strong vibration, moving viscous media) it
may be necessary to secure the screw connection, e�g� by a screw retaining
compound�
Substances such as screw retaining compounds may migrate into the
medium�
Make sure that they are harmless�
When using mechanical means of securing (e�g� tooth lock washer), protruding
edges must be avoided� They may cause interference reflection�

18
6.2.2 Installation of the coaxial pipe
This subchapter is only relevant if the unit is to be operated with a coaxial probe�
The coaxial pipe and the rod must be of the same end length� The coaxial
pipe can be shortened (→ 6.3.2).
►Screw the rod to the unit and tighten it�
Recommended tightening torque: 4 Nm�
►Slide the sensor seal (A) onto the thread�
►Slide the coaxial pipe (B) onto the rod� Carefully
centre it and carefully move the rod through the
centring piece (C) (for lengths > 140 cm through
both centring pieces) of the coaxial pipe� Do not
damage the centring pieces�
►Screw onto the sensor thread and tighten�
A
C
B
32
32

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6.3 Shortening of the probe
6.3.1 How to shorten the rod and determine its length L
The rod can be shortened to adapt the probe to different tank heights�
Ensure that the probe length is never below the minimum permissible probe
length of 10 cm (Lmin)! The unit does not support probe lengths below 10
cm� If shorter probes are used, measurement errors can occur�
Proceed as follows:
►Screw the rod to the unit�
►Mark the desired length (L) on the rod� The
reference point is the lower edge of the process
connection�
►Remove the rod from the unit�
►Shorten the rod at the mark�
►Remove all burrs and sharp edges�
►Screw the rod to the unit again and tighten it�
Recommended tightening torque: 4 Nm�
►Precisely measure the probe length L, note the
value� It must be entered during parameter setting
of the unit (→ 10.2).
Lmin
L
Lmin= 10 cm
6.3.2 Shortening of the coaxial pipe
The coaxial pipe and the rod must be of the same end length:

20
Fig.: 6-6
►Remove fastening bracket and
centring piece (A, B)�
►Shorten the coaxial pipe to the
requested length: LK= L + 9 mm�
►After shortening, at least one hole
(C) for insertion of the fixing bracket
has to be left�
►Remove all burrs and sharp edges�
►Insert centring piece (A) at the
lower end of the pipe and attach it
using the fixing bracket (B) at the
lower hole (C)�
AB
C
LK= length of the coaxial pipe
L = length of the rod from the lower edge
of the process connection (→ 6.3.1)
6.3.3 Determination of the rod length L when coaxial probes are used
Only relevant if the rod length L (→ 6.3.1) is unknown:
►Measure the exact total length LK of the coaxial pipe (→ fig. 6-6, on the right).
►Deduct 9 mm from the total length of the coaxial pipe: LK– 9 mm = L
► Note down L. It must be entered during parameter setting of the unit (→ 10.2).
6.4 Installation of the unit with single probe
For the correct function when used with single probe, the unit needs a
large enough metal launching plate� It is necessary for transferring the
microwave pulse to the tank with optimum transmission power� The flange
plates that are available as accessories are not sufficient as launching
plates�
For installation in closed metal tanks, the tank lid serves as a launching plate
(R in fig� 6-7 and 6-11)� 2 ways of installation are possible:
• Screw in a G¾ process connection in the tank lid (→ 6.4.1).
• Installation in the tank lid using a flange plate, e�g� for tanks with thin walls
(→ 6.4.2).
Furthermore, installation in open tanks (→ 6.4.3) and plastic tanks is possible
(→ 6.4.4).
Table of contents
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